Cloth board and method for making same



June 27, N KARP CLOTH BOARD AND METHOD FOR MAKING SAME Filed June FIG.

FIG 5 INVENTOR.

NORMAN KARP Pea/gm, +7

FIG.6

ATTORNEYS United States Patent 3,327,844 CLOTH BOARD AND METHOD FORMAKING SAME Norman Kai-p, 106 Lincoln Parkway, Lowell, Mass. 01851 FiledJune 3, 1964, Ser. No. 372,223 7 Claims. (Cl. 206-50) This inventionrelates to an improved cloth board of the doubled roll reel type and animproved method for making the same.

It has heretofore been proposed to make such cloth boards of a singlethickness of material, but to build up the thickness of each end byvarious expedients such as separate, individual end strips or byattaching a hollow end piece. For example, in U.S, Patent 1,899,195 toHeath of Feb. 28, 1933 a single ply body of solid paperboard is providedwith a superposed, narrow strip at each end, secured in place to form asubstantial thickness and a label is secured on the upper and lowerfaces of the builtup end portions.

Devices of this type are disposable and reduction of cost of manufacturetogether with reduction of cost of materials are of extreme importancein the art. The various devices shown in prior patents or presently inuse for the purpose have certain disadvantages especially in the wastageof material in forming the parts and in the rela tively high cost of theparts. As far as I am aware, the trade presently makes much use of twosuperposed plies of corrugated paperboard, connected at each end by aglued, folded label, as a disposable doubled roll reel and does not makemuch use of other types of reel.

In this invention the principal object is to provide a reel made from asingle ply of corrugated paperboard having single ply exposed side edgesbut having thickened ends by reason of integral, hingedly-connected, endflaps slit, but not severed, from the single plies folded back over theends of the single ply and held in place by a layer of adhesive andpreferably by other securing means. The structure of the invention thusnot only eliminates the cost of a second ply of material, therebyreducing the requisite amount of board needed for each reel by at leasttwenty-five percent, but the end flaps are slit from the single plyitself and cannot be misjoined, disoriented or likely to slip withrelation to the main body.

Another object of the invention is to provide a unitary, low cost clothboard formed from a rectangular, over length blank of corrugatedpaperboard having longitudinal side edge free of doubling or folds,wherein the flutes run longitudinally of a single thickness of the boardand each end is thickened by at least one integral, folded end flap slitfrom, and overfolded onto the board and securely aflixed thereto.

A further object of the invention is to provide a method for making lowcost doubled roll reels wherein a single ply, rectangular blank ofcorrugated paperboard 3,327,844 Patented June 27, 1967 FIG. 4 is a viewsimilar to FIG. 3 showing the end flaps overfolded, adhered and entirelycovered by the end labels.

FIG. 5 is a view similar to FIG. 2 showing an embodiment in which twoend flaps are oppositely slit at each end of the board, and

FIG. 6 is .a view similar to FIG. 3 showing the board of FIG. 4, folded,adhered and covered at each end to form three plies.

A preferred embodiment of the invention is shown in FIG. 1 wherein thedoubled roll reel 20 is formed of low cost corrugated paperboardmaterial 21, in a single ply. The material 21 includes an upper liner22, a lower liner 23 and the flutes 24, which preferably extendlongitudinally of the main body 25 of the reel. In the deviceillustrated the corrugated material includes two sets of flutes,separated by a liner but it will be apparent that any of theconventional corrugated boards may be used, which have both upper andlower liners. As shown in the drawing the blank 27 is flat andrectangular with two opposite, longer sides and two opposite, shortersides, or ends, the side and end edges being single ply and exposing theflutes in the usual manner of sheets cut from corrugated paperboard.

The blank 27 is several inches longer than the final product, and formedof a single ply of material 21. As shown in FIGURE 2, the first andcritical step is the slitting of the blank, along lines parallel to andspaced inwardly from the ends 28 and 29, from the outside face 31 of oneliner 23 to the inside face 32 of the other liner 22. The knives 33 and34, or other suitable cutting or scoring device, thus form the slitlines 35 and 36 which in turn define fold lines 37 and 38 for theresulting foldable end flaps 40 and 41, connected by webs of the upperliner 22 while still integral with the main body 25. In subsequentglueing, folding and covering steps control of the end flaps is not lostand the overfolded flaps are exactly positioned because of the hingeconnection at the web along the fold lines 37 and 38.

As shown in FIGURE 2 the. next step in making the reel 20 is theapplication of a layer of adhesive 42 and 43 along the outer face 44 ofthe upper liner 22 of body 25, in the area which will be occupied by theend flaps 40 and 41, when overfolded. Preferably the adhesive 42 and 43is of the hot melt type, such as Thermogrip, a product of United ShoeMachinery Corp. of Beverly, Massachusetts, and may be applied by anysuitable adhesive applying means as the slit blanks 27 are advancedalong the paper line of a folding and glueing machine of conventionaltype.

The end flaps 40 and 41 are then overfolded through an angle of 180 onthe fold line 37 or 38 into superposed position overlying the adjacentportion of the face 44 and is transversely slit at each end to formfoldable end flaps, I

the flaps are overfolded to form multi ply ends on the board and theflaps are secured in place by means such as a hot melt adhesive and thenat least partially covered by a foldable end label.

Other objects and advantages of the invention will be apparent from theclaims, the description of the drawing and from the drawing in which:

- FIG. l is a perspective view of a doubled roll reel constructed inaccordance with the invention.

FIG. 2 is a side elevation showing the step of slitting a single ply ofcorrugated board to form foldable, hingedly connected end flaps.

'FIG.' 3 is a view similar to FIG. 2 showing the end flaps overfolded,adhered and partially covered by the end labels.

overlying the adhesive strips 42 or 43, so that ends=of double thicknessare formed. When the end flaps 40 and 41 are overfolded, the cut flutesand liners along the slit liner 35 and 36 are exposed. The adhesive 42and 43 secures the flaps in folded position while the blanks 27 areadvanced along the paper line of a folding machine and until the finalstep of applying the end covering labels 46 and 47 is completed.

As shown in FIGURE 3, each end label such as 46 is formed of foldablepaper, sheet material such as cardboard 48, precreased along lines 50and 51 to fit over the ends of the reels. Staples 49, rivets or'similarmeans, may be used to hold the end labels 46 in place.

As shown in FIGURE 4 end labels47 are formed of thin, low cost, foldablesheet material such as cardboard 48, pre-creased along lines 50, 51, 52,and 53 to snugly fit over, and cover the exposed, slit, flutes anddouble ply ends of the reel. The entire inner face 54 of each label 46or 47 may be covered with a layer of adhesive so that the panels of thelabels, defined by the crease lines will adhere to the :correspondingfaces of the corrugated board.

However the terminal ends 55 and 56 of the label 47 extend inwardlyalong the main body 25 and are adhered by a layer of adhesive at 57 and58 to the faces 44 and 31 .to not only cover the ends but also to keepthe flaps overopposite end, by knives 63 and 64 from oppositedirections, to form end flaps 65 and 66, corresponding to the flaps 40and 41, and an additional end flap 67 or 68 at each end of the reel.

Two layers of hot melt adhesive 69 and 70 are applied as shown, and thetwo end flaps such as 65 and 68 at each end are folded as shown on theirintegral webs 72 and 73 to form multi ply ends of triple thickness. Eachprecreased end label, such as 74, has its terminal ends 76 and 77adhered to the main body 78 of the resulting reel 80 in the same manneras described above.

I claim:

1. A cloth winding board of the doubled roll reel type, said boardcomprising:

an elongated, single ply rectangular strip of corrugated paperboardhaving a pair of opposite, longer, single ply, sides, free of doublingand folds, a pair of opposite, shorter ends, said paperboard includingan upper liner and a lower liner, and flutes extending longitudinallyfrom end to end thereof, in parallelism with said longer sides;

said strip being slit along lines parallel to, and equally spacedinwardly from said ends, and said slits extending from the outer face ofone said liner to the inner face of the other said liner to define apair of integral, hingedly-connected, slit; end flaps;

said endflaps being overfolded along the line of said slits to overliesaid strip and form relatively thick ends thereon, with the slit linesof said strip exposed;

a layer of adhesive bonding each said flap to the adjaoent face of saidstrip;

a pair of pre-creased, paper labels, each folded around one of saidrelatively thick ends and at least partially covering the same whileentirely covering said exposed slit lines;

and means aflixing said labels in said position on said ends.

2. A cloth winding board as specified in claim 1 wherein:

each said label includes oppositely disposed, terminal portions eachoverlying andengaging one of said liners inwardly from the adjacentrelatively thick ends;

adhesive means adhesively securing said terminal portions to saidliners.

3. An improved doubled roll reel comprising:

, an elongated, rectangular, single ply body of fluted corrugatedpaperboard, said body having two opposite longer sides with single plyedges free of folds and two opposite shorter ends, said body beingpartially slit along lines parallel to, and spaced inwardly from, eachsaid opposite end thereof to define a pair of oppositely disposed,hingedly-connected end flaps;

said end flaps being overfolded on said lines to form a double ply ateach end of said single ply body;

a pre-creased paper end label at least partially cove-ring each saiddouble ply end; and

means securing said labels and flaps to said single ply body,

' 4. An improved doubled roll reel comprising:

a single ply rectangular blank of corrugated paperboard having oppositelongitudinal edges, free of folds, flutes extending in parallelism withsaid longitudinal edges and opposite lateral edges;

said rectangularblank being slit laterally proximate each oppositelateral edge thereof to divide said blank into a single ply main bodyand at least one hingedly connected, integral end flap folded back intosuperposed position on said body at each opposite end thereof to formmulti ply ends thereon;

a layer of adhesive bonding the said multi plies to each other and tosaid body;and

a pre-creased paper label folded over each said multi ply end andcovering the same, the terminal portions of said label being adhered tothe opposite faces of said single ply main body.

5. The method of making a doubled roll reel frorn a single ply ofcorrugated paperboard which comprises the steps of:

forming a flat rectangular blank from said corrugated paperboard with apair of opposite shorter ends and a pair of opposite longer sides ofgreater length than desired, the side and end edges of said blank beingfree of folds and exposing the flutes of said paperboard;

slitting said black along transverse lines proximate, and parallel to,each opposite end from the outside face of one liner to the inside faceof the other liner to form a single ply main body of the desired lengthwith a pair of integral, opposite hingedly connected, foldable endflaps;

then applying a layer of adhesive to said board in position to adheresaid flaps in overfolded position; and

then overfolding said end flaps through an angle of into adheredposition overlying said main body to form multi ply, integral endsthereon.

6. A method as specified in claim 5, plus the step of:

pre-creasing a pair of end labels to each define a plurality of panelsadapted to overlie one of the said multi ply integral ends of said reel;and

securing one said end label over each opposite multi ply end of saidboard to at least partially cover the same.

7.. A cloth winding board of the doubled roll reel type comprising:

an elongated, single strip of corrugated paperboard including an upperliner and a lower liner, and flutes extending longitudinally from end toend thereof;

said strip being slit along two parallel lines at each said end,- saidtwo slits being each from an opposite direction and each slit extendingfrom the outer face of one said liner to the inner face of the othersaid liner, to define a pair of integral, hingedly-connected, end flaps.at each end of said strip;

the inner end flap at each end being overfolded along the line of theinner slit to overlie said strip and the outer end flap at each endbeing overfolded along the line of the outer slit to overlie said innerflap to thereby form relatively thick ends of triple thickness on saidstrip;

a layer of adhesive bonding each said overfolded outer flap to theadjacent inner flap and a layer of adhesive bonding each said inner flapto the adjacent face of said strip;

a pair of labels each folded around one of said ends of triple thicknessand at least partially covering the same; and

means aflixing said labels in said position on said ends.

References Cited UNITED STATES PATENTS LOUIS G, MANCENE, PrimaryExaminer.

1. A CLOTH WINDING BOARD OF THE DOUBLED ROLL REEL TYPE, SAID BOARDCOMPRISING: AN ELONGATED, SINGLE PLY RECTANGULAR STRIP OF CORRUGATEDPAPERBOARD HAVING A PAIR OF OPPOSITE, LONGER, SINGLE PLY, SIDES, FREE OFDOUBLING AND FOLDS, A PAIR OF OPPOSITE, SHORTER ENDS, SAID PAPERBOARDINCLUDING AN UPPER LINER AND A LOWER LINER, AND FLUTES EXTENDINGLONGITUDINALLY FROM END TO END THEREOF, IN PARALLELISM WITH SAID LONGERSIDES; SAID STRIP BEING SLIT ALONG LINES PARALLEL TO, AND EQUALLY SPACEDINWARDLY FROM SAID ENDS, AND SAID SLITS EXTENDING FROM THE OUTER FACE OFONE SAID LINER TO THE INNER FACE OF THE OTHER SAID LINER TO DEFINE APAIR OF INTEGRAL, HINGEDLY-CONNECTED, SLIT; END FLAPS; SAID END FLAPSBEING OVERFOLDED ALONG THE LINE OF SAID SLITS TO OVERLIE SAID STRIP ANDFORM RELATIVELY THICK ENDS THEREON, WITH THE SLIT LINES OF SAID STRIPEXPOSED; A LAYER OF ADHESIVE BONDING EACH SAID FLAP TO THE ADJACENT FACEOF SAID STRIP; A PAIR OF PRE-CREASED, PAPER LABELS, EACH FOLDED AROUNDONE OF SAID RELATIVELY THICK ENDS AND AT LEAST PARTIALLY COVERING THESAME WHILE ENTIRELY COVERING SAID EXPOSED SLIT LINES; AND MEANS AFFIXINGSAID LABELS IN SAID POSITION ON SAID ENDS.